series atp electric chemical injection pump operating manual

Series ATP Reciprocating Drive - Dual or Single Head

With Adjustable Stroke Length

Operating Manual

CP-MAN-PRD-ATP REV00 EFF. DATE 04/01/19 of 12

Series ATP

Electric Chemical Injection Pump

Operating Manual

CheckPoint Headquarters CheckPoint UK CP Pumps & Systems FZE

21356 Marion Lane C2 Lombard Centre Shed 2, Warehouses 7 & 8

Mandeville, Louisiana 70471 Kirkhill Place, Kirkhill Industrial Estate RAK Technology Park | P.O. Box 54796

United States of America Dyce, Aberdeen AB21 0GU Scotland Ras Al Khaimah | UAE

+1 (504) 340-0770 +44 (0)1224 775205 +971 (4) 8806278



Operating Manual


TABLE OF CONTENTS

1. SYSTEM REQUIREMENTS 3

1.1 Inspection .................................................................................................................................................... 3

1.2 Storage......................................................................................................................................................... 3

1.3 Unpacking.................................................................................................................................................... 3

1.4 Safety ........................................................................................................................................................... 3

1.5 Location ....................................................................................................................................................... 3

1.6 Typical Installation Schematic ................................................................................................................... 4

1.7 Connect chemical and process lines to checks ......................................................................................... 4

2. MOTOR INSTALLATION 5

2.1 Motor Requirements .................................................................................................................................. 5

3. INJECTION HEAD ASSEMBLY 6

3.1 Adding an Injection Head. ......................................................................................................................... 7

4. STROKE LENGTH ADJUSTMENT 9

4.1 Adjusting the stroke length ....................................................................................................................... 9

5. OPERATION 10

5.1 Initial Startup ............................................................................................................................................ 11

6. TROUBLESHOOTING 11

6.1 Pump does not stroke .............................................................................................................................. 11

6.2 Drive is excessively noisy ......................................................................................................................... 11

6.3 Miscellaneous ............................................................................................................................................ 12



Operating Manual


1. SYSTEM REQUIREMENTS

1.1 Inspection

1.1.1 Before installation, please inspect the pump carefully. If the pump appears to have sustained damage in

transit, call your CheckPoint Authorized Distributor or CheckPoint Customer Service directly at +1 (504) 340-0770

to report and confirm damage. If it is determined that damage occurred in transit, a carrier claim will be required.

1.2 Storage

The Series ATP pump has been thoroughly tested at the CheckPoint factory prior to shipment. This testing may

leave residual fluids in the pump head. Although our pumps can be placed in service without environmental

protection, we suggest that they are stored indoors until being commissioned.

1.3 Unpacking

The ATP pump can be shipped as a single-head or dual-head pump. Please ensure that unpackaged pumps are

securely placed in a safe area. Refer to the CheckPoint Quick Setup Guide for installation of the ATP pump.

1.4 Safety

The Series ATP can produce high rod loads. All CheckPoint pump heads used with the ATP are designed to

provide cover plates to minimize pinch points. Use of the ATP with another brand of pump head is not

recommended and may present safety hazards.

1.5 Location

1.5.1 For safe and continuous operation, locate the pump with supplied base on a stable surface with sufficient

access for the operator.

1.5.2 CheckPoint requires horizontal mounting for the Series ATP. Improper mounting could result in poor drive

performance and difficulty during priming. The Series ATP base is provided to ensure proper orientation.

1.5.3 The pump may be mounted to a skid or other surface in a number of ways; however, clamping around the

outside of the drive is not recommended. Proper mounting techniques increase accessibility during maintenance

and troubleshooting.



Operating Manual


1.6 Typical Installation Schematic

FIGURE 1: TYPICAL INSTALLATION

CheckPoint offers Series ATP pump packages, which contain all necessary components indicated within the Package Limit Line in Figure 1. CheckPoint can also supply pump packages that contain ALL components indicated in Figure 1, including the tank, mounted on a single skid, with or without full leak containment.

1. Suction Line Block Valve 4. CheckPoint Calibration Gauge* 7. PRV – Discharge Lline 10. Discharge Check Valve*

2. CheckPoint Chemical Filter* 5. Tank Gauge 8. CheckPoint Series ATP Chemical Pump

3. Calibration Gauge Block Valve 6. Discharge Line Block Valve 9. Discharge Pressure Gauge

All items in Figure 1 can be purchased from CheckPoint. Call today for our latest prices on pumps, gauges, packages and other components.

*CheckPoint OEM products

1.7 Connect chemical and process lines to checks

Always clean suction lines and check chemical containers to ensure that they are free of all foreign matter, sand,

sludge, or chemical buildup.

NOTE: Even new chemical tanks can contain debris, which may cause system damage. Removing foreign

debris from suction lines and chemical containers will substantially extend the life of the packing

and other pump components.



Operating Manual


NOTE: A presuction in-line chemical filter is strongly recommended to prevent early packing failure.

Abrasive particles carried into the pump through suction plumbing is a common cause of packing

failure. CheckPoint offers a range of chemical filters suitable for use with the Series ATP pump.

1.7.1 Suction Check

The attach point is a ¼” MNPT thread. Apply thread sealant, taking care to keep the sealant away from the suction

inlet port. Sealant entering the check could cause the pump to operate incorrectly.

1.7.2 Discharge Check

The attach point is a ¼” FNPT thread. Apply thread sealant, taking care to keep the sealant away from the process

line port. Sealant entering the process line could cause issues downstream.

2. MOTOR INSTALLATION

The base model Series ATP comes with the motor already installed. Should you need to remove the motor for any

reason, install per the motor install drawing located on the CP website.

Installation is made easier (though not required) using CheckPoint’s installation tool, available for purchase (insert

part # here).

2.1 Motor Requirements

2.1.1 The Series ATP drive input accepts a male a 5/8” shaft.

• CheckPoint recommends a motor/gear reducer combination not exceeding 120 rpm at the ATP drive input

shaft. The maximum-rated rotational speed of the ATP input shaft is 120 rpm. NEVER EXCEED 120 RPM.

2.1.2 Connect Power

• Special attention should be paid to motor type and location hazards prior to hookup. The electric motor

must be connected in accordance with all local regulations and area classifications and should include

overload protection.

• It is recommended that the Series ATP installation is equipped with an easily accessible “emergency off”

switch.



Operating Manual


3. INJECTION HEAD ASSEMBLY

The base-level Series ATP pump assembly comes with a single head attached to the drive assembly (shown in

Figure 2).

FIGURE 2: INJECTION HEAD ASSEMBLY

*Motor and Base Removed for Clarity



Operating Manual


3.1 Adding an Injection Head.

The base model Series ATP comes with a single head but can be easily converted to a double-headed

configuration. You will need the following assemblies:

Figure 3: Head Assembly - Typical Figure 4: Retainer Assembly – All Models

3.1.1 Install the retainer assembly (clamp screw towards the front cover) to the carriage assembly using (2) attach

screws.

FIGURE 5: RETAINER ASSEMBLY AND CARRIAGE ASSEMBLY INSTALLATION

*Motor and Base Removed for Clarity



Operating Manual


3.1.2 Install plunger, snap ring, and screw assembly.

• Loosen the clamp screw approximately ½-turn.

• Screw the adjusting nut into the retainer assembly.

NOTE: The adjusting nut screwed in until it bottoms out on the end plate is full-stroke.

FIGURE 6: PLUNGER, SNAP RING, AND SCREW ASSEMBLY INSTALLATION



Operating Manual


3.1.3 Attach head assembly

• Remove the two head bolts and install the thru drive housing wall.

• Add the approved grease on the tip of the plunger.

• Slide the head assembly over the plunger and tighten the head bolts to 20 in-lbs.

FIGURE 7: HEAD ASSEMBLY ATTACHMENT

4. STROKE LENGTH ADJUSTMENT

Both injection heads operate independently and have adjustable stroke lengths between 0” - 0.75”.

4.1 Adjusting the stroke length

Pump Delivery Volume is controlled by adjusting the stroke length. To change the stroke length, the adjusting nut

in the retainer assembly is screwed in or out depending upon the volume required. The retainer assembly block

has indicators for approximate percentage of stroke.

Max. stroke length ( ¾”) - Adjusting nut should be screwed in until it bottoms out on the end plate of the

carriage. Do not over-tighten nut.

Min. stroke length (0”) - Adjusting nut should be unscrewed until the bottom of adjusting nut is at the 0% mark.



Operating Manual


Adjust the stroke as directed below in Figures 8 and 9.

1. Turn off the drive system

2. Remove the front cover

3. Loosen the clamp screw ½-turn (or as required)

4. Insert the tool into the 3/16” adjusting nut hole

5. Rotate the adjusting nut to the desired stroke length (clockwise to increase stroke)

6. Restart the drive system

7. Check the flow rate

8. Once the desired flow is achieved, tighten the clamp screw.

NOTE: Very little clamping force is required to lock adjusting nut. Do not overtighten.

FIGURE 8: SHOWN AT 100% STROKE FIGURE 9: SHOWN AT 50% STROKE

5. OPERATION

The CheckPoint Series ATP drive requires no additional lubrication. The cam bearing is sealed, and the guide rods

have sufficient grease in the carriage assembly prior to shipment.

Pump Flow Rate – DC Motor

• The flow rate can be adjusted by changing the motor rpm and by changing the stroke length.

NOTE: Adjusting the motor’s rpm during operation will not damage the Series ATP pump. Refer to your

motor manufacturer’s manual to determine the effects of adjusting RPM during operation.

Pump Flow Rate – AC Motor

• The flow rate can be only adjusted by changing the stroke length.

End Plate



Operating Manual


5.1 Initial Startup

5.1.1 Ensure that no leaks are visible prior to startup.

5.1.2 Disconnect the power to the motor.

5.1.3 Remove the outer cover to gain access to the plunger adjustment screw.

NOTE: The pump was tested in-house prior to shipping, using water with 5% water-based lubricant. If the

residual liquid remaining in the pump from testing could cause issues with the chemical, flush the

head prior to use.

WARNING: PINCH POINTS EXIST INSIDE THE BOX. DISCONNECT POWER BEFORE REMOVING COVER.

5.1.4 Open the chemical supply and system pressure valves.

5.1.5 Start the motor.

5.1.6 Bleed the injection head.

5.1.7 Adjust the flow rate.

6. TROUBLESHOOTING

6.1 Pump does not stroke

6.1.1 Check the power to the motor.

6.1.2 Ensure that the required amount of power is supplied to the motor and that the motor is turned on.

6.1.3 Check to see if the motor power is too low.

6.1.4 Ensure proper motor sizing for the particular application. Contact CheckPoint or your Authorized CheckPoint

Distributor for sizing assistance.

6.1.5 Check to see if there is damage to the keyway.

6.1.6 A key may have sheared during an overload situation. Inspect all bores and keyways for damage or missing

components.

6.2 Drive is excessively noisy

6.2.1 Drive components may be worn.

6.2.2 The motor or gear reducer may be worn. Contact your drive component manufacturer.



Operating Manual


6.3 Miscellaneous

If you are experiencing an operating problem not listed above, or if none of the above troubleshooting actions solve

your operating problem, please contact your Authorized CheckPoint Distributor, or contact CheckPoint directly at

+1 (504) 340-0770 or [email protected]. We will work to assist you in determining the appropriate next steps.

Once CheckPoint has had the opportunity to assist you with troubleshooting your problem, please keep in mind

the following information regarding repairs.

6.3.1 CheckPoint offers exchange programs to keep you in service.

6.3.2 CheckPoint will ship you a rebuilt pump, which you will be able to install prior to sending us your existing

pump. Upon receipt of your pump, we will tear it down, rebuild it, and report to you our findings. We offer a fixed-

price exchange plan, an actual-cost plan, and a consigned exchange plan. Please contact CheckPoint to learn more

about our unique exchange services.

6.3.3 Although the Series ATP has been designed for easy operation and repair, the best way to ensure continued

reliable service is to have your pump repaired by CheckPoint’s factory. OEM repair services ensure CheckPoint quality

and reliability.

6.3.4 After your CheckPoint pump has been repaired, it should perform like new

6.3.5 If your pump is anything less than exceptional, call us to determine what can be done to restore the pump to

“like-new” performance.

6.3.6 Training sessions are available. CheckPoint strives to maintain excellence in all that we do, and we are happy

to share our knowledge with you. If you would like to train your employees regarding anything involving CheckPoint

Pumps & Systems, please contact us to discuss training options.

series atp electric chemical injection pump operating manual

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